Tamper-resistant marker and method of mounting same

ABSTRACT

A tamper-resistant marker is formed of metal sheet material from a substantially planar blank thereof having a perimeter and two faces. The marker has a flange extending therefrom about the perimeter in a direction substantially perpendicular to the faces. The marker also has indicia with raised portions on one of the two faces, the raised portions being raised in a direction opposite to that of the flange. Methods of manufacturing the marker and of mounting it on a surface are also disclosed.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to the marking of storm drains to alert members of the public to the dangers in dumping detrimental materials into waterways. More specifically, the invention relates to a tamper-resistant marker for this purpose and to a method of mounting the marker.

2. Description of the Prior Art

The U.S. Environmental Protection Agency (EPA) has directed the states to develop programs to educate the public about the dangers to the environment when materials that are harmful to the health and safety of living organisms are dumped into streets and driveways, eventually to be washed to storm drains to enter rivers, streams, and other waterways and, possibly, our drinking water system.

The education program includes the marking of storm drains which lead from roadways and ultimately to waterways. Currently, several methods are used to carry out this marking.

Firstly, stencils have been commonly used to apply a warning message to the surface of concrete or asphalt near the storm drain. However, the paints used typically weather poorly and have to be redone every few years. The spray painting itself is time consuming, and cannot be done in wet or cold weather, or in windy conditions. Moreover, the paint vapors are potentially harmful to the user. The resulting prints are messy, and leave a message less clear than desirable.

Alternatively, ceramic tile markers, which have been screen-printed with an appropriate message and glazed, may be applied with adhesives and cemented in place. Ceramic tile markers, however, are easy to crack in use and are expensive. Flat cast or metal markers have also been used in the past. These have good life expectancy, but are expensive to manufacture and difficult to read. Because of their flat backs, they often fail to adhere to the adhesives.

Finally, plastic domed markers are most often used to identify storm drains. They are made of a base material, such as vinyl or polycarbonate, screen-printed with an appropriate message, and die-cut into shape. The resulting blank is covered with a polyurethane coating having ultraviolet (UV) inhibitors to protect against damage caused by exposure to sunlight. This heavy, syrup-like coating flows to the edge of the blank and hardens. The resulting product has graphics under a clear plastic dome that thins near the edges. Adhesives, like liquid nails, may be used to apply the markers to various surfaces.

There are several problems associated with these plastic domed markers. Firstly, exposure to direct sunlight causes embrittlement in plastics. Secondly, daily temperature variations often cause the adhesive to fail on the undersurface of the marker because the flat vinyl surface is smooth and offers little bond to the adhesive. Finally, colorful, domed plastic markers are attractive and easily pried from the surfaces to which they are attached by vandals and others who like to collect them. A penknife or small screwdriver is all that is required for this purpose, as the plastic domed markers are flexible and can readily be peeled from the surface to which they are applied once an edge is exposed.

The present invention is directed toward these shortcomings of the prior art and provides a tamper-resistant marker which cannot be as readily removed from a surface as those of the prior art.

SUMMARY OF THE INVENTION

Accordingly, the present invention is a tamper-resistant marker which comprises a blank made of metal sheet material. The blank is substantially flat and has a perimeter, two faces, and a flange extending therefrom about the perimeter in a direction substantially perpendicular to the faces. The blank also had indicia with raised portions on one of the two faces. The portions in question are raised in a direction opposite that of the flange. The areas between the raised portions may be painted to make the indicia more visible or legible, as the case may be.

As will be discussed below, the marker is mounted on a surface by cutting a groove thereinto having the shape of the flange extending around the perimeter of the blank. The flange resides in the groove below the level of the surface when mounted, making it difficult for a vandal to remove the marker.

The present invention also includes a method for manufacturing the tamper-resistant marker. The method comprises the steps of providing a blank of sheet metal, the blank having two faces and a perimeter, and of embossing indicia having raised portions onto one of the two faces of the blank. The method finally includes the step of forming a flange about the perimeter in a direction substantially perpendicular to the faces and in a direction opposite to that of the raised portions of the indicia.

Finally, the present invention includes a method of mounting the tamper-resistant marker on a surface. The method comprises the step of providing a marker having a substantially planar face and having a perimeter with a flange extending therefrom in a direction perpendicular to the face. The method also includes the step of cutting a groove into the surface onto which the marker is to be mounted. The groove conforms to the perimeter of the marker to accommodate the flange when the marker is installed on the surface.

Finally, an adhesive is applied onto the surface within the area defined by the groove, and the marker is pressed into the adhesive with the flange disposed in the groove.

The present invention will now be described in more complete detail with frequent reference being made to the figures identified below.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of a marker of the present invention;

FIG. 2 is a cross sectional view of the marker taken as indicated in FIG. 1;

FIG. 3 is a perspective view of a hole saw having a coaxial drill;

FIG. 4 is a partly cross-sectional, partly perspective view of a marker when installed; and

FIG. 5 is a perspective view of an installed marker.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Turning now to these figures, FIG. 1 shows a plan view of a marker 10 of the variety used in the practice of the present invention. FIG. 2 is an enlarged cross section thereof taken as indicated in FIG. 1.

The marker 10 is made of a metal, such as aluminum, brass or stainless steel, in heavy, 16-gauge (0.060-inch thick), blank sheets. Embossing dies form the flat blanks into deep three-dimensional disks or plates with raised copy, such as that on marker 10. A high tonnage power press, rated at 400 tons, is used for this purpose. The embossing adds strength to the metal material, often equivalent to doubling its thickness.

After embossing, the oversized plate is placed upon a blanking die that forms a dome, drawing the sides of the blank rearward to form an approximately 0.125-inch-deep dish- or cup-like shape just before it cuts the round blanks. The flange 12 formed in this operation is shown in FIG. 2, along with the embossed pattern 14, which is what may be seen of the design shown in FIG. 1 when viewed in cross section.

The shaped blanks, which may, for example, be 4.0-inch-diameter disks, are then deburred by sanding the cut edges or tumbling the disk in an abrasive medium.

After cleaning, the disks are placed upon an anvil nest and an abrasive pad, scotchbrite or emery cloth is rotated upon the face, to give a prism-spin appearance that reflects light and gives a high-quality appearance to the disk. At the same time, this operation applies a fine, uniform circular scratch to the surface and background of the disk which improves the adhesion of paint to be applied thereon.

A baking enamel containing ultraviolet inhibitors is spray-painted onto the surface and, while still wet, the plate is placed upon a conveyor belt that transports the product under a series of rollers having a solvent-absorbing paper to remove the wet paint from the raised portions of the embossed surface leaving the background in a painted and contrasting color. Alternatively, the paint may be removed from the raised portions of the embossed surface after curing with an abrasive sanding disk.

The plate is then baked at high temperatures to cure the paint and make it hard.

Alternatively, the flat blanks may be screen-printed with a color-contrasting background prior to embossing in registration with the screen-printed background. One or more colors may be applied in this manner. The blank may also be baked prior to the embossing step in this alternative.

The resulting finished product is distinctive, easy to read, has a high-quality appearance and, when compared to any other existing storm drain marker, gives the appearance of a product of much higher cost. The product with embossed-copy permanence has a life expectancy of more than thirty years, that is, its three-dimensional copy will be readable for over thirty years, two or more times longer than other products in use today.

The marker 10 may be mounted onto a concrete or other surface in the following manner. The surface may be a flat or plane surface, and may also be the curved or flat surface of a utility pole of concrete, wood or fiberglass. Referring to FIG. 3, a hole saw 20 having a diameter substantially equal to that of the marker 10 may be used to make a shallow circular groove into the surface on which the marker 10 is to be mounted. For centering purposes, and to accommodate a bolt for securing the marker 10 on the surface, the hole saw 20 has a drill 22 with a carbide bit 24. Using a power tool, the hole saw 20 and carbide bit 24 can be used to drill a center hole, perhaps to a depth of 1.0 inch, in the center of a circular groove having a depth nominally in a range from 0.0625 to 0.125 inch into the concrete, asphalt or other surface where the marker 10 is to be mounted. The purpose of the circular groove is to accommodate the flange 12 on the marker 10.

Upon completion of the drilling process, dust and chips are blown or brushed out. An adhesive or epoxy is then applied to fill the drilled hole and the area inside the circular groove. The marker 10 is then centered over the circular groove, lining up flange 12 therewith, and pressed down. As a consequence, the leading edge 14 or the flange 12 will be below the surface of the concrete or asphalt and the marker 10 will be embedded in the surface, presenting a much lower tripping hazard than other mounting methods.

FIG. 4 is a partly cross-sectional and partly perspective view of a marker 30 having a somewhat different design from marker 10. The marker 30 has been installed in the manner described above. Flange 32 is disposed in circular groove 44, and, as such, the leading edge 34 of the flange 32 is below the surface 40 of the concrete, asphalt or other material. An adhesive or epoxy 42 is used to hold the marker 30 to the surface 40. Because the marker 30, like marker 10 described above, has embossed areas which increase the surface area of the underside, the adhesive or epoxy 42 has increased area to bond both to the underside of the marker 30 and surface 40. Also shown is the optional bolt 36 which is secured within hole 46 by adhesive or epoxy 42.

FIG. 5 is a perspective view of marker 10, which lacks a bolt 36, installed on a surface 40 of concrete, asphalt or the like. Little adhesive or epoxy 42 may be seen around the perimeter of the marker 10. Because the flange 12 of marker 10 is within a circular groove 44 into surface 40, an implement, such as a screw driver or penknife, cannot reach below leading edge 14 to pry the marker 10 away. When embedded into concrete or asphalt in this manner, a snow plow scraping the top surface thereof will not dislodge the marker 10 as its flange 12 is firmly mounted below the level of the surface 40.

Modifications to the above would be obvious to those of ordinary skill in the art, but would not bring the invention so modified beyond the scope of the appended claims. 

1. A method of mounting a tamper-resistant marker on a surface, said method comprising the steps of: providing a marker having a substantially planar face and having a perimeter with a flange extending therefrom in a direction perpendicular to said face; cutting a groove into said surface, said groove conforming to said perimeter of said marker so that said groove accommodates said flange; applying an adhesive onto said surface within an area defined by said groove; and pressing said marker onto said adhesive with said flange disposed in said groove.
 2. A method as claimed in claim 1, wherein said marker is circular in shape, and wherein said cutting step is accomplished with a hole saw.
 3. A method as claimed in claim 2 further comprising the step of drilling a hole in the center of said groove cut by said hole saw.
 4. A method as claimed in claim 3 further comprising the step of providing said marker with a central hole.
 5. A method as claimed in claim 3 wherein said applying step includes filling said hole with said adhesive.
 6. A method as claimed in claim 4 further comprising the step of securing a bolt through said marker and into said hole.
 7. A method of manufacturing a tamper-resistant marker, said method comprising steps of: providing a blank of sheet metal, said blank having two faces and a perimeter; embossing indicia having raised portions onto one of said two faces of said blank; and forming a flange about said perimeter, said flange being in a direction substantially perpendicular to said faces and in a direction opposite to that of said raised portions of said indicia.
 8. A method as claimed in claim 7, wherein said step of forming a flange further includes cutting said blank into a circular form.
 9. A method as claimed in claim 7, wherein said step of forming a flange further includes forming a dome on said two faces convexly in a direction opposite to that of said flange.
 10. A method as claimed in claim 7 further comprising the step of deburring said flange.
 11. A method as claimed in claim 7 further comprising the step of cleaning said marker.
 12. A method as claimed in claim 7 further comprising the step of treating said face bearing said raised portions of said indicia with an abrasive medium.
 13. A method as claimed in claim 7 further comprising the steps of: applying a paint onto said face hearing said raised portions of said indicia; and curing said paint.
 14. A method as claimed in claim 13 further comprising the step, between said applying and curing steps, of removing said paint from said raised portions of said indicia.
 15. A method as claimed in claim 7, further comprising, before the embossing step, the step of screen-printing a background onto said blank in at least one color, and wherein said embossing step is done in registration with said screen-printed background.
 16. A method as claimed in claim 15, further comprising the step of baking said blank between said screen-printing and embossing steps.
 17. A tamper-resistant marker comprising: a blank of metal sheet material, said blank being substantially planar and having a perimeter and two faces, said blank having a flange extending therefrom about said perimeter in a direction substantially perpendicular to said faces, said blank further having indicia with raised portions on one of said two faces, said raised portions being opposite in direction to said flange.
 18. A tamper-resistant marker as claimed in claim 17, wherein said blank is circular.
 19. A tamper-resistant marker as claimed in claim 17, wherein said blank is domed convexly in a direction opposite to that of said flange.
 20. A tamper-resistant marker as claimed in claim 17, wherein said blank is of a metal selected from the group consisting of aluminum, brass and stainless steel.
 21. A tamper-resistant marker as claimed in claim 17, wherein said blank is 0.060 inch thick.
 22. A tamper-resistant marker as claimed in claim 17, wherein said flange is 0.125 inch high.
 23. A tamper-resistant marker as claimed in claim 17, wherein said face bearing said indicia with raised portions has a fine, uniform pattern of circular scratches.
 24. A tamper-resistant marker as claimed in claim 17, wherein said face hearing said indicia with raised portions is covered with a paint.
 25. A tamper-resistant marker as claimed in claim 24, wherein said paint is removed from said raised portions of said indicia.
 26. A tamper-resistant marker as claimed in claim 25, wherein said paint is removed with an abrasive sanding disk.
 27. A tamper-resistant marker as claimed in claim 24, wherein said paint includes ultraviolet (UV) inhibitors.
 28. A tamper-resistant marker as claimed in claim 17, wherein said face hearing said indicia with raised portions is screen-printed. 